Lower Intake Manifold Replacement

Lower Intake Manifold Replacement

Removal Procedure

Note:
* The intake manifold may be removed as an assembly. Do not remove the specific intake manifold components unless component service is required.
* It is not necessary to remove the upper intake manifold in order to remove the lower intake manifold.
* Do not allow dirt or debris to enter the fuel system. Ensure that the ends of the fuel system are properly sealed.
* Do not disassemble the central sequential fuel injection (SFI) unit, unless service is required.

1. Remove the engine cover. Refer to Engine Cover Replacement (Service and Repair).
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
3. Drain the cooling system. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.
4. Remove the fuel pipes/hoses. Refer to Fuel Line Replacement - Engine (Fuel Line Replacement - Engine).
5. Remove the ignition coil assembly. Refer to Ignition Coil Replacement (Service and Repair).
6. Remove the evaporative emission (EVAP) canister tube. Refer to Evaporative Emission Line Replacement - Engine (Evaporative Emission Line Replacement - Engine).




7. Open the heater outlet hose clamp and remove the hose from the intake manifold.




8. Open the heater inlet hose clamp and remove the hose from the water pump.
9. Reposition the heater inlet and outlet hoses.




10. Disconnect the following electrical connectors:

* The throttle body actuator (1)
* The manifold absolute pressure (MAP) sensor (2)
* The evaporative emission (EVAP) canister purge solenoid valve (3)

11. Disconnect the A/C pressure switch, if equipped.




12. Disconnect the control port injector module (1).




13. Disconnect the oil pressure sensor electrical connector (1).




14. Remove the engine wiring harness ground nut and ground wire (1) from the rear of the right cylinder head.




15. Remove the stud (1) holding the engine wiring harness bracket.
16. Reposition the engine wiring harness with the bracket aside.




17. Remove the positive crankcase ventilation (PCV) valve hose from the valve cover and rocker cover.
18. Disconnect the power brake booster vacuum hose from the vacuum fitting.




19. Reposition the radiator inlet hose clamps.
20. Remove the radiator inlet hose (1) from the thermostat housing.




21. Reposition the water pump inlet hose clamps.
22. Remove the water pump inlet hose.




23. In order to remove the front intake manifold bolt, perform the following:

1. Remove the drive belt. Refer to Drive Belt Replacement (Service and Repair).
2. Loosen the power steering (P/S) pump rear bracket nut.
3. Remove the P/S pump rear bracket front nut.
4. Remove the bolts and the nut for the P/S pump bracket.
5. Leave the A/C compressor, if equipped, and the P/S pump on the bracket.
6. Slide the P/S pump bracket forward to access the front intake manifold bolt.




24. Remove the intake manifold - lower bolts.
25. Remove the intake manifold.
26. Remove and discard the intake manifold gaskets.
27. Clean and inspect the intake manifold - lower, if necessary. Refer to Intake Manifold Cleaning and Inspection (53. Intake Manifold Cleaning and Inspection).

Installation Procedure

Caution: Apply the proper amount of the sealant when assembling this component. Excessive use of the sealant can prohibit the component from sealing properly. A component that is not sealed properly can leak leading to extensive engine damage.




1. Apply a 4.0 mm (0.157 in) patch of adhesive to the cylinder head side of the intake manifold gasket at each end. Refer to Adhesives, Fluids, Lubricants, and Sealers (Adhesives, Fluids, Lubricants, and Sealers) for the correct part number.
Note: The intake manifold gasket must be installed while the adhesive is still wet to the touch.

2. Install the intake manifold gasket onto the cylinder head. Use the gasket locating pins in order to properly seat the gasket.





Note: The intake manifold must be installed and the fasteners tightened while the adhesive is still wet to the touch.

3. Apply a 5 mm (0.197 in) bead of adhesive to the front top of the engine block. Refer to Adhesives, Fluids, Lubricants, and Sealers (Adhesives, Fluids, Lubricants, and Sealers) for the correct part number.
4. Extend the adhesive bead 13 mm (0.50 in) up onto each intake manifold gasket.




5. Apply a 5 mm (0.197 in) bead of adhesive to the rear top of the engine block. Refer to Adhesives, Fluids, Lubricants, and Sealers (Adhesives, Fluids, Lubricants, and Sealers) for the correct part number.
6. Extend the adhesive bead 13 mm (0.50 in) up onto each intake manifold gasket.




7. Install the intake manifold.
8. If reusing the old fasteners, apply threadlock to the threads of the intake manifold - lower bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers (Adhesives, Fluids, Lubricants, and Sealers) for the correct part number.
9. Install the intake manifold - lower bolts.





Caution: Proper lower intake manifold fastener tightening sequence and torque is critical. Always follow the tightening sequence, and torque the intake manifold bolts using the 3 step method. Failing to do so may distort the crankshaft bearing bore alignment and cause damage to the crankshaft bearings.

Caution: Refer to Fastener Caution (Fastener Caution).

10. Tighten the intake manifold - lower bolts in the sequence shown.

1. Tighten the bolts a first pass to 3 Nm (27 lb in).
2. Tighten the bolts a second pass to 12 Nm (106 lb in).
3. Tighten the bolts a final pass to 15 Nm (11 lb ft).




11. Slide the P/S pump bracket rearward.
12. Install the bolts and the nut for the P/S pump bracket.
13. Install the P/S pump rear bracket front nut.
14. Tighten the P/S pump rear bracket nuts and bolts to 41 Nm (30 lb ft).
15. Install the drive belt. Refer to Drive Belt Replacement (Service and Repair).




16. Install the water pump inlet hose.
17. Position the water pump inlet hose clamps.




18. Install the radiator inlet hose (1) to the thermostat housing.
19. Position the radiator inlet hose clamps.
20. Connect the power brake booster vacuum hose to the vacuum fitting.




21. Install the PCV valve hose to the valve cover and rocker cover.




22. Position the engine wiring harness and bracket.
23. Install the engine wiring harness bracket stud (1) and tighten to 25 Nm (18 lb ft).
24. Install the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve and tighten to 9 Nm (80 lb in).




25. Install the engine wiring harness ground nut and ground wire (1) to the rear of the right cylinder head and tighten to 16 Nm (12 lb ft).
26. Install the EVAP canister tube. Refer to Evaporative Emission Line Replacement - Engine (Evaporative Emission Line Replacement - Engine).




27. Connect the oil pressure sensor electrical connector (1).




28. Connect the following electrical connectors:

* The EVAP canister purge solenoid valve (1)
* The MAP sensor




29. Connect the control port injector module (1).




30. Connect A/C compressor clutch, if equipped.
31. Connect the following electrical connectors:

* The EVAP canister purge solenoid valve (3)
* The MAP sensor (2)
* The throttle body actuator (1)




32. Position the heater inlet and outlet hoses.
33. Open the heater inlet hose clamp and install the hose to the water pump.




34. Open the heater outlet hose clamp and install the hose to the intake manifold.
35. Install the fuel pipes/hoses. Refer to Fuel Line Replacement - Engine (Fuel Line Replacement - Engine).
36. Install the ignition coil assembly. Refer to Ignition Coil Replacement (Service and Repair).
37. Fill the cooling system. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.
38. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
39. Install the engine cover. Refer to Engine Cover Replacement (Service and Repair).